Electric actuator

ABSTRACT

Provided is an electric actuator, including: a drive part (2); a motion conversion mechanism part (3) configured to convert a rotary motion from the drive part (2) into a linear motion in an axial direction parallel with an output shaft of the drive part (2); a driving force transmission part (4) configured to transmit a driving force from the drive part (2) to the motion conversion mechanism part (3); and a motion-conversion-mechanism support part (5) configured to support the motion conversion mechanism part (3), and wherein the drive part (2) and the motion-conversion-mechanism support part (5) are capable of being coupled to and decoupled from the driving force transmission part (4).

TECHNICAL FIELD

The present invention relates to an electric actuator.

BACKGROUND ART

In recent years, electrification of automobiles and the like has been promoted for power saving and reduction in fuel consumption. For example, a system for operating an automatic transmission, a brake, a steering wheel, and the like of the automobile with use of power of an electric motor has been developed and brought to the market. As an electric actuator for use in such an application, there has been known an electric linear actuator employing a ball screw mechanism configured to convert a rotary motion of a motor into a motion in a linear direction (Patent Literature 1).

CITATION LIST

Patent Literature 1: JP 5243018 B2

SUMMARY OF INVENTION

Technical Problem

However, when series production of the electric actuator is prepared for multiple-type deployment, when cases and component parts of the electric actuator are individually designed in accordance with specifications of a system to which the electric actuator is applied, there is a problem of causing increase in production cost.

The present invention has been made in view of the above-mentioned problem, and therefore has an object to provide an electric actuator suitable for reduction in cost and series production.

Solution to Problem

According to one embodiment of the present invention, as technical measures for achieving the above-mentioned object, there is provided an electric actuator, comprising: a drive part; a motion conversion mechanism part configured to convert a rotary motion from the drive part into a linear motion in an axial direction parallel with an output shaft of the drive part; a driving force transmission part configured to transmit a driving force from the drive part to the motion conversion mechanism part; and a motion-conversion-mechanism support part configured to support the motion conversion mechanism part, wherein the drive part comprises a driving motor and a motor case configured to accommodate the driving motor, wherein the driving force transmission part comprises a transmission gear mechanism configured to transmit the driving force from the drive part to the motion conversion mechanism part, and a transmission gear case configured to accommodate the transmission gear mechanism, wherein the motion-conversion-mechanism support part comprises a support bearing configured to support the motion conversion mechanism part, and a bearing case configured to accommodate the support bearing, and wherein the drive part and the motion-conversion-mechanism support part are capable of being coupled to and decoupled from the driving force transmission part.

As described above, the drive part and the motion-conversion-mechanism support part are capable of being coupled to and decoupled from the driving force transmission part. Thus, an electric actuator adapted to various applications and usages can be formed by replacing one or a plurality of those parts by parts having another configuration, or newly adding another part between the respective parts, which is preferred for the series production. Moreover, for the series production, common parts can be applied without replacement, and the series production of the electric actuator can thus be achieved at a low cost.

The drive part may comprise a motor part and a speed reduction mechanism part. The motor part may comprise the driving motor and the motor case configured to accommodate the driving motor. The speed reduction mechanism part may comprise a speed reduction gear mechanism configured to reduce a speed of the driving force of the driving motor and output the driving force, and a speed reduction gear case configured to accommodate the speed reduction gear mechanism. In this case, the speed reduction mechanism part is capable of being coupled to and decoupled from the motor part and the driving force transmission part. Thus, anyone of the motor part and the speed reduction mechanism part can be replaced by a part having another configuration, or another part can be newly added therebetween in accordance with various applications and usages.

Further, according to one embodiment of the present invention, the electric actuator may further comprise a shaft case, which is configured to accommodate a shaft portion of the motion conversion mechanism part configured to perform the linear motion. In this case, the shaft case is capable of being coupled to and decoupled from the bearing case. Thus, the shaft case can be replaced by a part having another configuration, or another part can be newly added between the shaft case and the bearing case in accordance with various applications and usages. For example, a lock mechanism part configured to prevent the motion conversion mechanism part from driving may be provided to the shaft case.

Moreover, the drive part and the motion-conversion-mechanism support part are capable of being coupled to and decoupled from the driving force transmission part in a direction of the output shaft of the driving motor. Thus, an assembly operation for the parts can satisfactorily be carried out.

Advantageous Effects of Invention

According to the present invention, an electric actuator suitable for the reduction in cost and the series production can be achieved.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a vertical sectional view of an electric actuator according to one embodiment of the present invention.

FIG. 2 is an external perspective view of the electric actuator.

FIG. 3 is an exploded perspective view of the electric actuator.

FIG. 4 is a view of a motor case as seen from an opening portion side.

FIG. 5 is a transverse sectional view as seen in a direction indicated by the arrows of the line A-A in FIG. 1.

FIG. 6 is an exploded perspective view of a speed reduction mechanism part.

FIG. 7 is an exploded perspective view of a shaft case and a lock mechanism part mounted thereto.

FIG. 8 is a transverse sectional view as seen in a direction indicated by the arrows of the line B-B in FIG. 1.

FIG. 9 is a transverse sectional view as seen in a direction indicated by the arrows of the line C-C in FIG. 1.

FIG. 10 is a control block diagram of the electric actuator.

FIG. 11 is a control block diagram of the electric actuator.

FIG. 12 is a vertical sectional view of the electric actuator according to another embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

Now, description is made of the present invention with reference to the accompanying drawings. In the respective drawings for illustrating the present invention, components such as members and component parts having the same functions or shapes are denoted by the same reference symbols as long as the components can be distinguished, and description thereof is therefore omitted after the description is made once.

FIG. 1 is a vertical sectional view for illustrating an assembled state of an electric actuator according to one embodiment of the present invention. FIG. 2 is an external perspective view for illustrating the assembled state of the electric actuator. FIG. 3 is an exploded perspective view of the electric actuator.

As illustrated in FIG. 1, an electric actuator 1 of this embodiment mainly comprises a drive part 2, a motion conversion mechanism part 3, a driving force transmission part 4, a motion-conversion-mechanism support part 5, an operation part 6, and a lock mechanism part 7. The drive part 2 is configured to generate a driving force. The motion conversion mechanism part 3 is configured to convert a rotary motion from the drive part 2 into a linear motion. The driving force transmission part 4 is configured to transmit the driving force from the drive part 2 to the motion conversion mechanism part 3. The motion-conversion-mechanism support part 5 is configured to support the motion conversion mechanism part 3. The operation part 6 is configured to output the motion of the motion conversion mechanism part 3. The lock mechanism part 7 is configured to prevent the motion conversion mechanism part 3 from driving. Moreover, the drive part 2 comprises a motor part 8 and a speed reduction mechanism part 9.

Each of the parts forming the electric actuator 1 has a case. Component parts are accommodated in each of the cases. Specifically, the motor part 8 comprises a motor case 11 configured to accommodate a driving motor 10. The speed reduction mechanism part 9 comprises a speed reduction gear case 17 configured to accommodate a speed reduction gear mechanism 16. Moreover, the driving force transmission part 4 comprises a transmission gear case 29 configured to accommodate a transmission gear mechanism 28. The motion-conversion-mechanism support part 5 comprises a bearing case 41 configured to accommodate a support bearing 40. Further, respective pairs of the motor part 8 and the speed reduction mechanism part 9, the speed reduction mechanism part 9 and the driving force transmission part 4, and the driving force transmission part 4 and the motion-conversion-mechanism support part 5 are configured to be capable of being coupled to and decoupled from one another while the pairs are accommodated in the cases. Further, a shaft case 50 is configured to be capable of being coupled to and decoupled from the bearing case 41. Now, description is made of detailed configurations of the respective parts forming the electric actuator 1.

The motor part 8 mainly comprises the driving motor (DC motor) 10 and the motor case 11. The driving motor 10 is configured to drive the motion conversion mechanism part 3. The motor case 11 is configured to accommodate the driving motor 10. The motor case 11 comprises a case main body 12 and a projecting portion 13. The case main body 12 has a bottomed cylindrical shape, and is configured to accommodate the driving motor 10 therein. The projecting portion 13 projects from a bottom portion 12 a of the case main body 12 to the outside. The projecting portion 13 has a hole portion 13 a which communicates to an internal space of the case main body 12. The hole portion 13 a is sealed by a seal member 14 that is made of resin and covers an outer surface of the projecting portion 13.

Under a state in which the driving motor 10 is inserted from an opening portion 12 d of the case main body 12 into an inside of the case main body 12, an end surface of the driving motor 10 on an inner side in an insertion direction is held in abutment against the bottom portion 12 a of the case main body 12. Moreover, a fitting hole 12 c is formed in a center portion of the bottom portion 12 a. A projection 10 b of the driving motor 10 in the inner side in the insertion direction is fitted to the fitting hole 12 c, thereby preventing interference of a rear end (left end portion in FIG. 1) of an output shaft 10 a projecting from the projection 10 b with the bottom portion 12 a of the motor case 11. Further, an inner peripheral surface of a peripheral wall portion 12 b of the case main body 12 is reduced in diameter in a tapered shape from the opening portion 12 d side toward the bottom portion 12 a side. When the driving motor 10 is inserted into the case main body 12, an outer peripheral surface of the driving motor 10 on the inner side in the insertion direction comes into contact with the inner peripheral surface of the peripheral wall portion 12 b. With this configuration, the driving motor 10 is supported through the contact with the inner peripheral surface of the case main body 12 and the fitting to the fitting hole 12 c under the state in which the driving motor 10 is inserted into the case main body 12.

Moreover, as illustrated in FIG. 4, which is a view of the motor case 11 as seen from the opening portion 12 d side, a pair of bus bars 15 configured to connect the driving motor 10 to a power supply is mounted to the case main body 12. One end portion 15 a of each of the bus bars 15 is connected to a motor terminal 10 c through crimping, and another end portion 15 b is exposed from the case main body 12 to the outside (see FIG. 2 and FIG. 3). The end portions 15 b of the bus bars 15 exposed to the outside are connected to the power supply.

Next, description is made of the speed reduction mechanism part 9.

As illustrated in FIG. 1, the speed reduction mechanism part 9 mainly comprises the speed reduction gear mechanism 16 and the speed reduction gear case 17. The speed reduction gear mechanism 16 is configured to reduce the speed of the driving force of the driving motor 10 and output the driving force. The speed reduction gear case 17 is configured to accommodate the speed reduction gear mechanism 16. The speed reduction gear mechanism 16 is formed of a planetary-gear speed reduction mechanism 18 comprising a plurality of gears and the like. A detailed configuration of the planetary-gear speed reduction mechanism 18 is described later.

The speed reduction gear case 17 has an accommodating recessed portion 17 a configured to accommodate the planetary-gear speed reduction mechanism 18 from an opposite side of the driving motor 10. Moreover, the speed reduction gear case 17 is formed so as to enable a motor adaptor 19 serving as a motor mounting member to be mounted thereto. The motor adaptor 19 is a tubular member, and a projection 10 d of the driving motor 10 on an output side (right side in FIG. 1) is inserted into and fitted to an inner peripheral surface of the motor adaptor 19. The speed reduction gear case 17 has a fitting hole 17 b to which the motor adaptor 19 is fitted. The motor adaptor 19 is inserted from the driving motor 10 side into the fitting hole 17 b and mounted to the fitting hole 17 b.

The speed reduction gear case 17 is configured to be capable of being fitted to the motor case 11 and the transmission gear case 29 described later and arranged on the opposite side of the motor case 11. A portion of the speed reduction gear case 17 arranged on the motor case 11 side is internally fitted to the opening portion 12 d side of the motor case 11. A portion of the speed reduction gear case 17 arranged on the transmission gear case 29 side is externally fitted to the transmission gear case 29. Moreover, the speed reduction gear case 17 is fastened to the driving motor 10 through bolts 21 (see FIG. 3 and FIG. 6) together with the motor adaptor 19 while being fitted to the motor case 11. On the driving motor 10 side of the speed reduction gear case 17, there are formed recessed portions 17 c configured to prevent interference with the motor terminals 10 c projecting from the driving motor 10 and with the end portions 15 a of the bus bars 15 crimped to the motor terminals 10 c while the speed reduction gear case 17 and the motor case 11 are fitted to each other. Moreover, a mounting groove 17 d configured to mount an O ring 20 is formed in an outer peripheral surface (fitting surface) of the speed reduction gear case 17 to be fitted to an inner peripheral surface of the motor case 11.

Next, description is made of the motion conversion mechanism part 3.

The motion conversion mechanism part 3 is formed of a ball screw 22. The ball screw 22 mainly comprises a ball screw nut 23, a ball screw shaft 24, a large number of balls 25, and deflectors 26. The ball screw nut 23 serves as a rotary body. The ball screw shaft 24 is a shaft portion performing a linear motion. The deflectors 26 serve as circulation members. Spiral grooves 23 a and 24 a are respectively formed in an inner peripheral surface of the ball screw nut 23 and an outer peripheral surface of the ball screw shaft 24. The balls 25 are loaded between both of the spiral grooves 23 a and 24 a, and the deflectors 26 are assembled therebetween. With this configuration, the balls 25 in two rows circulate.

The ball screw nut 23 receives the driving force from the driving motor 10, to thereby rotate in a forward direction or a backward direction. Meanwhile, the rotation of the ball screw shaft 24 is restricted by a pin 27 that is provided on a rear end portion (right end portion in FIG. 1) thereof and serves as a rotation restriction member. Therefore, when the ball screw nut 23 rotates, the balls 25 circulate along both the spiral grooves 23 a and 24 a and the deflectors 26, and the ball screw shaft 24 advances and retreats in the axial direction. FIG. 1 is a view for illustrating a state in which the ball screw shaft 24 is arranged at an initial position given when the ball screw shaft 24 retreats most to the right side of FIG. 1. Moreover, the ball screw shaft 24 is arranged in parallel with the output shaft 10 a of the driving motor 10. The rotary motion from the driving motor 10 is converted into a linear motion in the axial direction parallel with the output shaft 10 a by the ball screw shaft 24. A distal end portion (left end portion in FIG. 1) of the ball screw shaft 24 in an advancing direction functions as the operation part (actuator head) 6 configured to operate an object device to be operated

Next, description is made of the driving force transmission part 4.

The driving force transmission part 4 mainly comprises the transmission gear mechanism 28 and the transmission gear case 29. The transmission gear mechanism 28 is configured to transmit the driving force from the driving motor 10 of the drive part 2 to the ball screw 22 being the motion conversion mechanism part 3. The transmission gear case 29 is configured to accommodate the transmission gear mechanism 28. The transmission gear mechanism 28 comprises a drive gear 30 on a drive side and a driven gear 31 on a driven side meshing with the drive gear 30.

A gear boss 32 is press-fitted to a rotation center portion of the drive gear 30. The drive gear 30 is rotatably supported through intermediation of the gear boss 32 by two rolling bearings 33 and 34 mounted to both the transmission gear case 29 and the bearing case 41 described later. Meanwhile, the driven gear 31 is press-fitted and fixed to the outer peripheral surface of the ball screw nut 23. When the driving force from the driving motor 10 is transmitted to the drive gear 30 through intermediation of the planetary-gear speed reduction mechanism 18, the driven gear 31 and the ball screw nut 23 integrally rotate, and the ball screw shaft 24 advances and retreats.

The transmission gear case 29 comprises an accommodating recessed portion 29 a configured to accommodate the drive gear 30 and the driven gear 31 therein. Moreover, the transmission gear case 29 has an insertion hole 29 b through which the gear boss 32 is inserted. On an inner peripheral surface of the insertion hole 29 b, there is formed a bearing mounting surface 29 c to which the one rolling bearing 33 configured to support the gear boss 32 is mounted. Moreover, the transmission gear case 29 comprises an annular projection 29 d fitted to an inner peripheral surface of the speed reduction gear case 17. In an outer peripheral surface (fitting surface) of the annular projection 29 d, there is formed a mounting groove 29 e configured to mount an O ring 35. Moreover, in a surface of the transmission gear case 29 on the bearing case 41 side, there is formed a fitting recessed portion 29 f in a groove form fitted to the bearing case 41.

Moreover, the transmission gear case 29 comprises a cylindrical portion 29 g projecting toward a distal end portion side (left side in FIG. 1) of the ball screw shaft 24. The cylindrical portion 29 g is a portion arranged so as to cover a periphery of the ball screw shaft 24 under a state in which the driven gear 31 is accommodated in the transmission gear case 29, and the ball screw 22 is assembled to the driven gear 31. A boot 36 configured to prevent foreign substances from entering the transmission gear case 29 is mounted between the cylindrical portion 29 g and the ball screw shaft 24. The boot 36 comprises a large-diameter end portion 36 a, a small-diameter end portion 36 b, and a bellows portion 36 c, which connects the large-diameter end portion 36 a and the small-diameter end portion 36 b to each other, and expands and contracts in the axial direction. The large-diameter end portion 36 a is fixed to a mounting portion of an outer peripheral surface of the cylindrical portion 29 g by tightening a boot band 37. The small-diameter end portion 36 b is fixed to a mounting portion of the outer peripheral surface of the ball screw shaft 24 by tightening a boot band 38. Moreover, the cylindrical portion 29 g has a vent hole 29 h which is configured to cause the air to communicate between an inside and an outside of the boot 36 when the boot 36 expands and contracts. Moreover, a boot cover 39 arranged around the boot 36 is provided integrally with the motor case 11.

Next, description is made of the motion-conversion-mechanism support part 5.

The motion-conversion-mechanism support part 5 mainly comprises the support bearing 40 and the bearing case 41. The support bearing 40 is configured to support the ball screw 22 being the motion conversion mechanism part 3. The bearing case 41 is configured to accommodate the support bearing 40. The support bearing 40 is formed of a back-to-back double-row angular contact ball bearing comprising an outer ring 42, an inner ring 43, and balls 44 in a plurality of rows interposed therebetween as main components.

The support bearing 40 is accommodated in a sleeve 45 formed integrally with the bearing case 41, and is fixed through a snap ring 46 mounted to an inner peripheral surface of the sleeve 45. Moreover, the support bearing 40 is fixed by being press-fitted to an outer peripheral surface of the ball screw nut 23 on a rear end side (right side in FIG. 1) of the ball screw shaft 24 with respect to the driven gear 31. A movement in the axial direction of the support bearing 40 and the driven gear 31 fixed to the outer peripheral surface of the ball screw nut 23 is restricted by a restriction projection 23 b formed on the ball screw nut 23 on the driven gear 31 side and a restriction member 47 mounted on the support bearing 40 side. The restriction member 47 comprises a pair of semicircular members, and is mounted to the outer peripheral surface of the ball screw nut 23 while the semicircular members are combined in an annular form. Further, a pressing collar 48 and a snap ring 49 are mounted to the outer peripheral surface of the ball screw nut 23. The pressing collar 48 is configured to hold the restriction member 47. The snap ring 49 is configured to prevent the pressing collar 48 from falling off in the axial direction.

On the transmission gear case 29 side of the bearing case 41, there is formed a protruding portion 41 a configured to be fitted to the fitting recessed portion 29 f of the transmission gear case 29. Moreover, on the transmission gear case 29 side of the bearing case 41, there is formed a gear boss accommodating portion 41 b configured to accommodate a part of the gear boss 32 projecting from the transmission gear case 29 under a state in which the bearing case 41 is fitted to the transmission gear case 29. On an inner peripheral surface of the gear boss accommodating portion 41 b, there is formed a bearing mounting surface 41 c which is configured to mount the rolling bearing 34 configured to support the gear boss 32.

On an opposite side of the bearing case 41 with respect to the transmission gear case 29 side, the shaft case 50 having a bottomed tubular shape configured to accommodate a rear end portion side (right end portion side in FIG. 1) of the ball screw shaft 24 is formed so as to be capable of being fastened through bolts 51 (see FIG. 3). In an abutment surface of the shaft case 50 against the bearing case 41, there is formed a mounting groove 50 a configured to mount an O ring 52. Moreover, in an inner peripheral surface of the shaft case 50, guide grooves 50 b into which both end portions of the pin 27 provided on the ball screw shaft 24 are formed so as to extend in the axial direction. A guide collar 53 is rotatably mounted to each of the both end portions of the pin 27. When the ball screw shaft 24 advances and retreats in the axial direction, the guide collars 53 move along the guide grooves 50 b while rotating.

As illustrated in FIG. 3, bolt insertion holes 11 a, 17 e, 29 i, and 41 d for inserting bolts 54 configured to assemble and fasten the motor case 11, the speed reduction gear case 17, the transmission gear case 29, and the bearing case 41 are formed in outer peripheries of the respective cases in a radial direction. Further, through holes 29 j and 41 e configured to mount the assembled electric actuator 1 to an installation location are formed in the outer peripheries in the radial direction of both of the transmission gear case 29 and the bearing case 41.

Now, description is made of the planetary-gear speed reduction mechanism 18 with reference to FIG. 1, FIG. 5, and FIG. 6.

FIG. 5 is a transverse sectional view as seen in a direction indicated by the arrows of the line A-A in FIG. 1. FIG. 6 is an exploded perspective view of the planetary-gear speed reduction mechanism 18.

The planetary-gear speed reduction mechanism 18 comprises a ring gear 55, a sun gear 56, a plurality of planetary gears 57, a planetary gear carrier 58 (see FIG. 1), and planetary gear holders 59 (see FIG. 1). The ring gear 55 comprises a plurality of protrusions 55 a projecting in the axial direction. Engagement recessed portions 17 f as many as the protrusions 55 a are formed in the accommodating recessed portion 17 a of the speed reduction gear case 17 (see FIG. 1). Through assembly of the protrusions 55 a of the ring gear 55 to the engagement recessed portions 17 f of the speed reduction gear case 17 while the protrusions 55 a and the engagement recessed portions 17 f are in phase, the ring gear 55 is accommodated in the speed reduction gear case 17 while the rotation of the ring gear 55 is stopped.

The sun gear 56 is arranged at the center of the ring gear 55. The output shaft 10 a of the driving motor 10 is press-fitted to the sun gear 56. Moreover, the respective planetary gears 57 are arranged between the ring gear 55 and the sun gear 56 so as to mesh with the ring gear 55 and the sun gear 56. The respective planetary gears 57 are rotatably supported by the planetary gear carrier 58 and the planetary gear holders 59. The planetary gear carrier 58 comprises a cylindrical portion 58 a at its center portion. The cylindrical portion 58 a is press-fitted between an outer peripheral surface of the gear boss 32 and an inner peripheral surface of the rolling bearing 33 (see FIG. 1). An annular collar 75 is mounted between an inner peripheral surface of the another rolling bearing 34 and the outer peripheral surface of the gear boss 32.

In the planetary-gear speed reduction mechanism 18 having the configuration described above, when the driving motor 10 performs the rotational drive, the sun gear 56 coupled to the output shaft 10 a of the driving motor 10 rotates, and, along with this rotation, the respective planetary gears 57 revolve along the ring gear 55 while rotating. Then, the planetary gear carrier 58 is rotated by the revolving motion of the planetary gears 57. With this, the rotation of the driving motor 10 is reduced in speed and transmitted to the drive gear 30, and a rotation torque increases. When the driving force is transmitted through the planetary-gear speed reduction mechanism 18 in such a manner, a high output of the ball screw shaft 24 can be obtained, and the driving motor 10 can be downsized.

Next, description is made of the lock mechanism part 7 with reference to FIG. 1, FIG. 7, and FIG. 8. FIG. 7 is an exploded perspective view of the shaft case 50 and the lock mechanism part 7 mounted thereto. FIG. 8 is a transverse sectional view as seen in a direction indicated by the arrows of the line B-B in FIG. 1.

The lock mechanism part 7 mainly comprises a lock member 60, a sliding screw nut 61, a sliding screw shaft 62, a lock-member fixation plate 63, a locking motor (DC motor) 64, and a spring 65. When the lock mechanism part 7 is to be assembled, first, the lock member 60 is fastened to the sliding screw nut 61 through intermediation of the lock-member fixation plate 63 with bolts 84 (see FIG. 7). Next, the locking motor 64 is accommodated in a holder portion 66 formed in the shaft case 50. The sliding screw shaft 62 is then mounted to an output shaft 64 a of the locking motor 64 projecting from the holder portion 66. Then, the spring 65 is arranged on an outer periphery of the sliding screw shaft 62, and the sliding screw nut 61 having the lock member 60 mounted thereto is mounted to the sliding screw shaft 62 through thread engagement. In such a manner, the assembly of the lock mechanism part 7 is completed.

The holder portion 66 is formed into a bottomed tubular shape, and a cap 67 is mounted on an opposite side of a bottom portion 66 a thereof. The locking motor 64 is held in abutment against the bottom portion 66 a of the holder portion 66 and an inner surface of the cap 67 under a state in which the locking motor 64 is inserted into the holder portion 66 and the cap 67 is mounted. Moreover, under this state, a projection 64 b of the locking motor 64 on an output side (left side in FIG. 1) is fitted to a fitting hole 66 c formed in the bottom portion 66 a of the holder portion 66. Both of an outer peripheral surface of the main body of the locking motor 64 and an inner peripheral surface of a peripheral wall portion 66 b of the holder portion 66 are formed into the same shapes, which are not cylindrical. Thus, the rotation of the locking motor 64 is restricted through the insertion of the locking motor 64 into the peripheral wall portion 66 b of the holder portion 66. Through accommodation of the locking motor 64 in the holder portion 66 in such a manner, the locking motor 64 is held by the holder portion 66, and the entire lock mechanism part 7 is held. Moreover, the cap 67 has a hole portion 67 a configured to insert cables 68 connected to motor terminals 64 d of the locking motor 64 (see FIG. 8).

Lock-mechanism accommodating recessed portions 66 d and 41 f are respectively formed in a portion of the shaft case 50 at which the holder portion 66 is formed and a portion of the bearing case 41 opposed thereto. A through hole 41 g is formed in the lock-mechanism accommodating recessed portion 41 f on the bearing case 41 side. As illustrated in FIG. 1, a part of the output shaft 64 a of the locking motor 64, the sliding screw shaft 62, the sliding screw nut 61, the lock-member fixation plate 63, the spring 65, and the lock member 60, which project from the holder portion 66, are accommodated in the lock-mechanism accommodating recessed portions 66 d and 41 f, and a distal end portion side of the lock member 60 is inserted into the through hole 41 g under a state in which the shaft case 50 is mounted to the bearing case 41. Moreover, the spring 65 is compressed in the axial direction between the bottom portion 66 a of the holder portion 66 and the lock-member fixation plate 63 under the state in which the shaft case 50 is mounted to the bearing case 41. The lock member 60 is always urged in an advancing direction (left side in FIG. 1) by the compressed spring 65.

The drive gear 30 is arranged in the advancing direction of the lock member 60. The drive gear 30 has engagement holes 30 a with which the distal end portion of the lock member 60 can be engaged. As illustrated in FIG. 9, which is a transverse sectional view as seen in a direction indicated by the arrows of the line C-C in FIG. 1, the plurality of engagement holes 30 a are formed in a circumferential direction of the drive gear 30. The rotation of the drive gear 30 is restricted through the engagement of the lock member 60 with any one of those engagement holes 30 a. Moreover, a tilted surface 30 b is formed at an entrance portion of each of the engagement holes 30 a, and the lock member 60 is thus smoothly inserted into the engagement hole 30 a along the tilted surface 30 b.

A lock sensor 69 configured to detect a locking state is mounted to the bearing case 41 (see FIG. 8). The lock sensor 69 comprises a contact element 69 a formed of an elastic member such as a plate spring. When the lock member 60 advances to be engaged with the engagement hole 30 a (brought into a locking state), the lock member 60 pushes the contact element 69 a so that the lock sensor 69 detects the locking state.

Now, description is made of an operation of the lock mechanism part 7.

When power is not supplied to the locking motor 64, the lock member 60 is held at the advanced position by the spring 65, and is in the locking state in which the distal end portion of the lock member 60 is engaged with the engagement hole 30 a of the drive gear 30. When the power is supplied to the driving motor 10 in order to start the driving of the ball screw shaft 24 in this state, the power is also supplied to the locking motor 64, and the locking motor 64 drives the lock member 60 in a retreating direction. With this, the sliding screw shaft 62 rotates. Meanwhile, the rotation of the sliding screw nut 61 is restricted through the insertion of the flat-plate-shaped distal end portion of the lock member 60 into the through hole 41 g. Thus, when the sliding screw shaft 62 rotates, the sliding screw nut 61 retreats against the urging force of the spring 65, and the lock member 60 retreats integrally with the sliding screw nut 61. With this, the distal end portion of the lock member 60 is disengaged from the engagement hole 30 a of the drive gear 30, and the locking state is thus released. In this way, while the ball screw shaft 24 is being driven, the lock member 60 is held at the retreated position, and the drive gear 30 is thus held in the unlocked state.

After that, when the supply of power to the driving motor 10 is shut off and the drive of the ball screw shaft 24 is thus stopped, the supply of power to the locking motor 64 is also shut off. With this, the driving force for causing the lock member 60 to retreat is no longer generated, and the lock member 60 is thus pushed to move in the advancing direction by the spring 65. Then, the locking state is brought about through the engagement of the distal end portion of the lock member 60 with the engagement hole 30 a of the drive gear 30, thereby restricting the rotation of the drive gear 30.

Through restriction of the rotation of the drive gear 30 by the lock member 60 in such a manner, the ball screw shaft 24 is held in the state in which the ball screw shaft 24 does not retreat. With this, even when an external force is input from the object device to be operated to the ball screw shaft 24 side, a position of the ball screw shaft 24 can be held at a predetermined position. This configuration is particularly preferred for a case in which the electric actuator is applied to an application that requires holding a position of the ball screw shaft 24.

In this embodiment, the lock member 60 is caused to retreat by driving the locking motor 64. Conversely, the locking motor 64 may be driven to cause the lock member 60 to advance. Moreover, the lock member 60 may be caused to advance and retreat by rotating the locking motor 64 forward and backward.

A stroke sensor 70 configured to detect a stroke of the ball screw shaft 24 is mounted to the electric actuator 1 of this embodiment (see FIG. 2 and FIG. 3). The stroke sensor 70 is mounted to a sensor base 71. The sensor base 71 is fastened and fixed through bolts 72 to a sensor case 76 formed on an outer peripheral surface between the motor case 11 and the boot cover 39. Meanwhile, a permanent magnet 73 serving as a sensor target is mounted to an outer peripheral surface of a portion of the ball screw shaft 24 covered with the boot 36 (see FIG. 1). In this embodiment, the permanent magnet 73 is mounted to the ball screw shaft 24 through intermediation of a cylindrical elastic member 74 cut apart at a portion in a peripheral direction. When the ball screw shaft 24 advances and retreats, a position of the magnet 73 with respect to the stroke sensor 70 changes, and the position of the ball screw shaft 24 in the axial direction can be recognized through the stroke sensor 70 detecting a change in direction of line of magnetic force that changes along with the change in position of the magnet 73.

Next, with reference to FIG. 10, description is made of feedback control using the stroke sensor 70.

As illustrated in FIG. 10, when a target value is transmitted to a control device 80, a control signal is transmitted from a controller 81 of the control device 80 to the driving motor 10. The target value is, for example, a stroke value calculated by an ECU provided at an upper position of a vehicle based on an operation amount when the operation amount is input to the ECU.

When the driving motor 10 receives the control signal, the driving motor 10 starts the rotational drive, and the driving force thereof is transmitted to the ball screw shaft 24 through intermediation of the planetary-gear speed reduction mechanism 18, the drive gear 30, the driven gear 31, and the ball screw nut 23, and the ball screw shaft 24 thus advances. With this, the object device to be operated arranged on the distal end portion side (actuator head side) of the ball screw shaft 24 is operated.

At this time, the stroke value (position in the axial direction) of the ball screw shaft 24 is detected by the stroke sensor 70. The detection value detected by the stroke sensor 70 is transmitted to a comparison portion 82 of the control device 80, and a difference between the detection value and the target value is calculated. Then, the driving motor 10 is driven until the detection value matches the target value. When the electric actuator 1 of this embodiment is applied to, for example, a shift-by-wire system, a shift position can reliably be controlled by feeding back the stroke value detected by the stroke sensor 70 to control the position of the ball screw shaft 24 in such a manner.

Next, with reference to FIG. 11, description is made of feedback control in a case in which a pressure sensor 83 is used in place of the stroke sensor 70.

As illustrated in FIG. 11, in this case, the pressure sensor 83 is provided for the object device to be operated. When the operation amount is input to the ECU provided at the upper position of the vehicle, the ECU calculates a required target value (pressure command value). When the target value is transmitted to the control device 80, and the control signal is transmitted from the controller 81 to the driving motor 10, the driving motor 10 starts the rotational drive. With this, the ball screw shaft 24 advances, and the object device to be operated arranged on the distal end portion side (actuator head side) of the ball screw shaft 24 is operated to pressurize.

An operation pressure of the ball screw shaft 24 at this time is detected by the pressure sensor 83, and the position of the ball screw shaft 24 is subjected to the feedback control based on the detection value and the target value as in the case of the use of the stroke sensor 70. When the electric actuator 1 of this embodiment is applied to, for example, a brake-by-wire system, a hydraulic pressure of a brake can reliably be controlled by feeding back the pressure value detected by the pressure sensor 83 to control the position of the ball screw shaft 24 in such a manner.

The configuration and the operation of the electric actuator 1 of this embodiment are as described above. Now, description is made of components suitable for a cost reduction and series production relating to the electric actuator 1 of this embodiment.

As described above, in the electric actuator 1 of this embodiment, respective pairs of the motor case 11 and the speed reduction gear case 17, the speed reduction gear case 17 and the transmission gear case 29, and the transmission gear case 29 and the bearing case 41 are configured to be capable of being coupled to and decoupled from one another. Therefore, the respective pairs of the motor part 8 and the speed reduction mechanism part 9, the speed reduction mechanism part 9 and the driving force transmission part 4, and the driving force transmission part 4 and the motion-conversion-mechanism support part 5 are also configured to be capable of being coupled to and decoupled from one another. Further, the shaft case 50 is configured to be capable of being coupled to and decoupled from the bearing case 41. In such a manner, the respective cases and the respective parts accommodated in or mounted to the cases are configured to be capable of being coupled and decoupled as the individual units. An electric actuator adapted to various applications and usages can thus be formed by replacing each unit by a unit having another configuration, newly adding another unit between the units, or omitting a part of the units, which is preferred for the series production. Moreover, upon the series production, common parts can be applied to form the electric actuator without replacement, and the series production of the electric actuator can thus be achieved at a low cost.

For example, when the speed reduction mechanism part 9 and the lock mechanism part 7 are not required, as illustrated in FIG. 12, the electric actuator 1 without the speed reduction mechanism part 9 and the lock mechanism part 7 can be formed. The electric actuator 1 illustrated in FIG. 12 is configured, compared with the electric actuator 1 illustrated in FIG. 1, by eliminating the speed reduction mechanism part 9, directly coupling the motor part 8 and the driving force transmission part 4 to each other, and replacing the shaft case 50 by one without the holder portion 66 to which the lock mechanism part 7 is mounted. In this case, the speed reduction mechanism part 9 is not provided. Thus, the output shaft 10 a of the driving motor 10 is press-fitted to the gear boss 32, and the rolling bearing 33 on the transmission gear case 29 side configured to support the gear boss 32 is omitted. Moreover, a member to be fitted to the motor adaptor 19, to which the driving motor 10 is mounted, is changed from the speed reduction gear case 17 to the transmission gear case 29, and is thus replaced by one having a different shape conforming to a fitting shape of the member to be fitted to the motor adaptor 19. The other configurations are the same as those of the embodiment illustrated in FIG. 1. The electric actuator 1 of the embodiment illustrated in FIG. 12 is controlled to operate basically in the same manner as in the embodiment illustrated in FIG. 1 except that the driving force from the driving motor 10 is directly transmitted to the driving force transmission part 4 without intermediation of the speed reduction mechanism part 9. Thus, description of the control and the operation is omitted.

As described above, the electric actuator 1 illustrated in FIG. 12 can be formed by replacing only a part of the components of the electric actuator 1 illustrated in FIG. 1, and the other many components can be the same components. Moreover, although not illustrated, other than the embodiments illustrated in FIG. 1 and FIG. 12, an electric actuator comprising only one of the speed reduction mechanism part 9 and the lock mechanism part 7 without another one of the speed reduction mechanism part 9 and the lock mechanism part 7 can be formed. Moreover, the shaft case 50 may be replaced by one different in size in accordance with a stroke length of the ball screw 22. Further, between the case in which the driving force is transmitted with the reduction in speed and the case in which the driving force is transmitted without the reduction in speed (case of transmission with a constant speed) between the drive gear 30 and the driven gear 31, a gear ratio of both of the gears 30 and 31 and a shape of the transmission gear case 29 may be changed.

In such a manner, with the electric actuator according to the present invention, only required parts can be changed, removed, or added in accordance with the application and specifications without changing common parts, and the electric actuator low in cost and excellent in versatility can thus be provided. With this, also in a case in which the electric actuator is deployed as a plurality of types for, for example, an electric parking brake mechanism for vehicles including two-wheeled vehicles, an electric/hydraulic brake mechanism, an electric shift change mechanism, and an electric power steering as well as a 2 WD/4 WD electric switching mechanism and an electric shift change mechanism for an outboard engine (for a vessel propulsion engine), the series production can be achieved at a low cost.

In particular, in the above-mentioned embodiments, all of an inner diameter on the opening portion 12 d side of the motor case 11, an outer diameter on the motor case 11 side of the speed reduction gear case 17, and an outer diameter on the speed reduction gear case 17 side of the transmission gear case 29 are formed into the same diameters, and the motor case 11 is thus configured to be capable of being fitted to both of the speed reduction gear case 17 and the transmission gear case 29. Therefore, even when the speed reduction mechanism part 9 is omitted, the motor part 8 and the driving force transmission part 4 can be coupled to each other only by replacing the motor adaptor 19 by another one. Moreover, the respective pairs of the drive part 2 and the driving force transmission part 4 (in the configuration comprising the speed reduction mechanism part 9, the respective pairs of the motor part 8 and the speed reduction mechanism part 9, and the speed reduction mechanism part 9 and the driving force transmission part 4), and the driving force transmission part 4 and the motion-conversion-mechanism support part 5, which are capable of being couple to and decoupled from one another, are configured to be capable of being coupled and decoupled in the direction of the output shaft of the driving motor 10. Thus, ease of assembly operation thereof is also excellent.

The motion conversion mechanism part 3 is not limited to the ball screw 22, and may be a sliding screw device. However, the ball screw 22 is more preferred in terms of reducing the rotation torque and downsizing the driving motor 10. Moreover, in the above-mentioned embodiments, although the configuration of using the double-row angular contact ball bearing as the support bearing 40 configured to support the motion conversion mechanism part 3 is exemplified, the support bearing 40 is not limited to this example. A pair of single-row angular contact ball bearings may be used in combination. Moreover, as the support bearing 40, in addition to the angular contact ball bearing, another double-row bearing using, for example, a deep groove ball bearing may be applied. Moreover, the speed reduction mechanism part 9 may be a speed reduction mechanism other than the planetary-gear speed reduction mechanism 18.

As described above, the present invention is not limited to the above-mentioned embodiments. As a matter of course, the present invention may be carried out in various modes without departing from the spirit of the present invention. The scope of the present invention is defined in claims, and encompasses equivalents described in claims and all changes within the scope of claims.

REFERENCE SIGNS LIST

-   1 electric actuator -   2 drive part -   3 motion conversion mechanism part -   4 driving force transmission part -   5 motion-conversion-mechanism support part -   6 operation part -   7 lock mechanism part -   8 motor part -   9 speed reduction mechanism part -   10 driving motor -   10 a output shaft -   11 motor case -   16 speed reduction gear mechanism -   17 speed reduction gear case -   28 transmission gear mechanism -   29 transmission gear case -   40 support bearing -   41 bearing case -   50 shaft case 

The invention claimed is:
 1. An electric actuator, comprising: a drive part; a motion conversion mechanism part configured to convert a rotary motion from the drive part into a linear motion in an axial direction parallel with an output shaft of the drive part; a driving force transmission part configured to transmit a driving force from the drive part to the motion conversion mechanism part; a motion-conversion-mechanism support part configured to support the motion conversion mechanism part; and a shaft case, which is configured to accommodate a shaft portion of the motion conversion mechanism part configured to perform the linear motion, wherein the drive part comprises a driving motor and a motor case configured to accommodate the driving motor, wherein the driving force transmission part comprises a transmission gear mechanism configured to transmit the driving force from the drive part to the motion conversion mechanism part, and a transmission gear case configured to accommodate the transmission gear mechanism, wherein the motion-conversion-mechanism support part comprises a support bearing configured to support the motion conversion mechanism part, and a bearing case configured to accommodate the support bearing, wherein the drive part and the motion-conversion-mechanism support part are capable of being coupled to and decoupled from the driving force transmission part, and wherein the shaft case is capable of being coupled to and decoupled from the bearing case from a side of the bearing case that is opposite to a side of the bearing case at which the transmission gear case is located.
 2. The electric actuator according to claim 1, wherein the drive part comprises a motor part and a speed reduction mechanism part, wherein the motor part comprises the driving motor and the motor case configured to accommodate the driving motor, wherein the speed reduction mechanism part comprises a speed reduction gear mechanism configured to reduce a speed of the driving force of the driving motor and output the driving force, and a speed reduction gear case configured to accommodate the speed reduction gear mechanism, and wherein the speed reduction mechanism part is capable of being coupled to and decoupled from the motor part and the driving force transmission part.
 3. The electric actuator according to claim 1, further comprising a lock mechanism part configured to prevent the motion conversion mechanism part from driving is provided to the shaft case.
 4. The electric actuator according to claim 1, wherein the drive part and the motion-conversion-mechanism support part are capable of being coupled to and decoupled from the driving force transmission part in a direction of the output shaft of the driving motor. 